smith



L. R. SMITH.

PROCESS OF MAKING INTEGRAL CROSS BAR BLANKS FOR VEHIC1.E FRAMES.

APPLICATION FILED APR. 1!. I919.

1,328,555. Patented Dec. 2,1919.

01- 0 ll/EM/ INVENTOR L. R. 6M1 TH ATTORNEYS,

pnrrnn snares Parana onnron LLOYD 1a. SMITH, or MILWAUKEE, WISCONSIN.

PROCESS OF MAKING INTEGRAL CRGSS-BAR BLANKS FOR VEHICLE-FRAMES}.

Specification of Letters Patent.

Patented Dec. a, rare.

Application filed April 11, 1919. Serial No. 289,187.

' which the invention pertains to make, use,

and practice the same, reference being had to the drawings hereto attached for disclosure as to certain details of construction by which my process may be carried out.

My invention relates to an electric welding process and is used in the production of sheet metal blanks from which the cross bars and otherflanged or channeled bars of automobile frames are made.

In many types of automobile frames, the contour of the blanks from which the cross bars are formed is of such varying and ir-v regular outline that an excessive amount of material is required for the production of such blanks. In other words, the rectangular area indicated by the extreme dimensions of the contoured blank exceeds the superficial area of such blank by as much as one hundred per cent. in some instances.

The amount of waste material or scrap following inevitably the operation of punching contoured blanks from metal plates or sheets, is, therefore, disproportionately large, when compared with the results attained.

This waste of material is directly due to the presence of gusset projections extending from the body of the blankin the plane of the latter, and at one or more sides thereof.

On account of the limited uses for the scrap which results from the punching of complete cross bar blanks from ,metal plates or sheets, the cost of the production of such blanks is rendered excessive, inasmuch as the greater part of the waste material must be disposed of as scrap.

The blanks are converted into channeled cross bars by bendingthe marginal portions at a right angle to the web, this drawing operation leaving the gusset projections in the plane of that marginal portionof which they are a part. In such position, the gussets act as braces or stayswhen the parts of the automobile frame are assembled and secured together.

My invention comprises the formation of what may be designated the body blank, it

having greater regularity of outline by reabar blank soconstructed lacks none of the elements of the rigidity and strength required in its uses.

By producing the body blank without the gusset projections, the dimensions of the blank in the direction of its width are greatly reduced, and the number of such blanks which may be punched from a metal plate or sheet is largely increased. The gusset projections may be produced from the scrap of the plate or sheet after the body blanks have been punched therefrom. These operations result in the practically complete utilization of the whole of the metal plate or sheet, so that the waste is reduced to a minimum.

In the accompanying drawings, I have shown a common form of cross bar blank, the showing being merely conventional, to enable a ready comparison to be made between the old method and my new method of producing blanks.

In the drawings,

Figure 1, shows the skeleton of a metal sheet or plate of given dimensions, the cross bar blanks having been punched therefrom, and indicating the excessive amount of scrap remaining, according to the old method of manufacture.

Fig. 2, is a similar view showing the increased number of blanks produced and the lessened amount of scrap remaining in the plate, resulting from the use of myinvention.

Fig. 3 is a view of a cross bar blank constituted of a body portion with the gusset projections welded thereto in accordance with my improvement.

Figs. 4 and 5, are fragmentary views showing modifi ations of the arrangement of the gusset projections with relation to the body blank.

Referring to the drawings, A, Fig. 1, indicates a metal sheet or plate from which cross bar blanks of approved contour have been punched. It will be observed that'the' formation of the gusset projections as integral parts of the blank necessitates a wide separation of the blanks along the central line of the plate, with the result that pieces electrical welding current will be applied.

and the parts will be heated to afusion atof waste material or scrap, a, of large proportions in the areas alternating with those from which the blanks are punched, are produced, and that such waste production is unavoidable.

In Fig. 2,713, indicates a metal plate or sheet of the dimensions of the plate A, in Fig. 1. In connection with this View, it will be seen thatan increased number of cross bar blanks, but formed without the gusset projections, has been punched .therefrom, and that the area of the waste or scrap, b, in the spacesintermediate the p'unchings is largely reduced. This will be apparent from a comparison of thetwo figures.

Specifically stated, the-maximum number of blanks of the contour shown which can be punched from the metal plate in Fig.1, is four, while the number of such blanks with the same general outlines which can be punched from the metal plate in Fig. 2,

the dimensions of the sheet in each case being-the same, is seven, ail-increase of seventy five per cent. in the productive output. At the same time, as hereinbefore indicated, the waste or scrap is reduced to a minimum.

In Fig. cross bar body blanks by the letter C, and the separately formed gusset projections by D and D. A blank C and two gussets D and D, will be assembled in the same plane, with their edges at the points of union in proximity to each other, such points being indicated 0? and d When so assembled an gether. I

In Fig. 4:, I have shown a modifiedmantheir meeting edges and. thus joined toner of attaching the gusset D to the body blank. In this figure, the parts are inter locked, as at 03 in addition to the welding operation. In Fig. 5, the welding line (Z. between the body blank andthe gusset D 1s at an angle from that shown in Fig. 3. It'iswithin thescope of my invention to arrange .the welding line at any desired 7 angle, and the latter may be varied to meet the exigencies existing in anyfparticular type of crossbar blank.

margins of the blank are to be folded in form ng the channeled cross bar. The folding line will not ordinarily be coincidentwith the-welding line, but the folding line may cross the welding line, if desired.

The h st bleak nd the. gusset r eliam .3, I have indicated one of the I I The dotted lines 7 1n Fig. 3, indicate the lines upon which the tobe welded thereto are held in their proper relative positions in a jig or carrier, by

means of which theyare presented to the welding devices, which latter may be of any approved construction.

In carrying out the operation of welding the gussets to the body blank, I prefer to vehicle frame cross bar blanksfromsheet metal with minimum waste of material,

which consists in cutting a sheet metal strip I to forma series. of gussetless and closely j located body blanks along contour which coincide-in the strip as to the side margins of successive blanks, separately cutting gusset'flanges, and subsequently integrally uniting the gussetfianges to the body blanks by placing themedgetoedge in the same plane, and electrically welding them together. I i I n 2. The method of forming integral cross bar blanks for automobile frames with mini mum waste of material, which consists in cutting a piece of sheet metal along lines which .destroy the integrity of the blank,

while permitting the severance of closely located gussetless members along coincide ing contour lines, separately 1 cutting the gusset members and subsequently uniting the body. and gusset members of each' individual cross bar by placingithem edge to: edge in the same plane, and restoring the integrity of the blank by electrically weld; ing the members together. I r

3; :The method of manufacturing integral cross bar blanks for vehicle frames, which I conslsts 1n cuttmg from a sheetof metal a succession of closely located and gussetless body blanks along coinciding contour lines.

withinterlocking provisions for the gussets,

I separately cutting gussetmembers with corresponding interlocking provisions, .as'sembling the. said elements in' the same lan 1n interlocked relation, and uniting thesaid elements by welding at the line of assembly. Inv testimony whereof,I have signed name at Milwaukee, NVisconsin, this 5th day of April, 1919. I II I I, I LLB. SMITH.

Witnessesi WzF. WOOLARD, 1 V 

